Method of forming decorative bodies



United States This invention relates to a method of forming raiseddecorative bodies on a surface to be decorated, and more particularly toa method of mass producing gretting cards having a novel raiseddecorative body of predeter mined shape and configuration aflixedthereto.

The present application is a continuation-in-part of my copendingapplication, Serial No. 592,272, filed June 19, 1956, now abandoned,entitled Method of Forming Decorative Bodies, which application is inturn a continuation-in-part of my then copending application, Serial No.497,721, filed March 29, 1955, now abandoned, en

'tled Decorative Articles of Manufacture, which application was in turna continuation-in-part of my then copending application, Serial No.457,131, filed September 20, 1954, now abandoned, entitled Compositionfor Simu+ lating Precious Stones and Method of Applying the Same.

Conventionally, greeting cards are formed with a dec orative printing ofpredetermined shape and design. Numerous printing techniques well knownin the art have been used to form designs of exotic color and form. Inmore expensive greeting cards, card decorating techniques have been usedby which materials other than ink such as, for example, felt fibers, maybe utilized to provide more unusual types of greeting cards.

Greeting card manufacturers also applied synthetic jewels or sequin-likematerials to the preprinted surfaces of greeting cards to satisfy themore esoteric demands of those customers who desire something differentin the greeting card line.

The conventional techniques of applying flocking material and syntheticjewels are time consuming, laborious and expensive. Conventionally,flocking is applied by first applying to the greeting card an adhesivein a predetermining pattern, spraying or otherwise applying a flockedmaterial to the greeting card and then allowing the adhesive to dry andthereby hold the flocked material to it. I Synthetic gems areconventionally applied by hand and the gems are adhered to the surfaceof the greeting card by means of an adhesive.

Prior to the present invention, many manufacturers of greeting cardsattempted to devise a method by means of which raised decorative bodieswhich simulate gems or jewels could be applied to greeting cards onamass production basis. it was their desire to manufacture a card whichhad the appearance of luxury at a relatively moderate price. The methodconventionally used required the use of a guide such as a stencil plateor the like through which a hardenable mass was introduced to thesurface of an object to be decorated. This mass was then hardened as byheat to form a decorative body. In order to maintain the mass in apredetermined shape the guide was left in position on the surface untilthe mass had sufliciently hardened to prevent the running thereof andthen the stencil plate was removed. The necessity of retaining thestencil plate or the like on the surface to be decorated until the masshad at least partially hardened increased the cost of production andlimited the output per stencil during a given time period. Thus,conventional techniques by which gem-like objects were applied to asurface to be decorated were expensive, time consuming and complicated.

It is, therefore, an object of this invention to provide a method bymeans of which raised decorative bodies simulating gems or jewels may beapplied readily and ecoatent. Q

nomically on a mass production basis to surfaces to be decorated.

It is another object of this invention to provide a method for formingraised decorative bodies from a liquid composition in which guide meansare required for only a short period of time.

It is still another object of this invention to provide a method forforming raised decorative bodies on surfaces to be decorated whichpermits the decoration of a great number of surfaces during a given timeperiod.

It is a further object of this invention to provide a method of formingdecorative bodies which eliminates the need for an adhesive andexpensive hand processing.

Still another object of this invention is to provide a method by meansof which decorative bodies of predetermined size and shape may bereadily and conveniently applied to greeting cards.

A more particular object of this invention is to provide a method bymeans of which clear plastic bodies having an entrapped substantiallyuniform layer of reflective material simulating thereby a jewel-likeappearance may be readily and conveniently secured to the surface of agreeting card in any predetermined pattern or position.

Other objects and advantages of the present invention will, it issubmitted, be apparent to those skilled in the art from the followingdetailed description of a preferred embodiment thereof.

Generally, the method which is the subject of this inventioncontemplates the formation of a substantially opaque resinouscomposition containing a thixotropic agent, the application of theresinous material to a surface to be decorated in predetermined shapeand form, and the curing of the material whereby a clear, transparentresinous material having a gem-like quality is formed which firmlyadheres to the surface.

More particularly, the method contemplates the use of particularpolyester monomer systems containing a thixotropic agent, a thermalresponsive catalyst and certain stabilizing agents; the application ofthe modified monomeric material to a greeting card, the said materialbeing formed and positioned by a stencil of predetermined shape andthickness; and the conversion of the opaque thixotropic monomer to asolid polymer by means of an accurately controlled time-temperature curecycle.

According to the present invention the guide means such as a stencilplate is made from a material to which the composition of the decorativebodies will not adhere when in liquid form. It has been found. that thiscondition is best met by using Teflon as the material of the stencilplate. Holes in the predetermined shape desired for the raiseddecorative bodies in accordance with the overall design of the Christmascards or the like are then cut into the stencil plate.

The entire stencil plate is preferably of standard length and width, soas to permit insertion into a frame which is hingedly attached to aworking surface. The paper sheet or the like which is to be decorated isthen placed on the working surface, the frame with the Teflon platetherein is lowered so that the stencil plate comes in contact with theupper surface of the sheet of paper or the like.

Suitable guides for the sheet of paper are provided on the workingsurface so as to obtain proper registration between the Teflon plate orguide means and the underlying sheet of paper. The liquid composition ofwhich the raised decorative bodies are to be formed is then introducedfrom the upper free face of the stencil plate so as to fill the holeswhich were previously cut into the stencil plate.

Care has to be taken that these holes are completely filled with theliquid composition. This can be done in any suitable manner known inthe-art such as by running a squeegee over the upper free surface of thestencil plate.

As soon as the fiowable thixotropic composition filled into the holes inthe stencil plate is sufficiently hardened to retain its shape, whichhappens practically immediately, the frame with the stencil plate isagain lifted. While the frame and stencil plate arrangement has beendescribed as hingedly connected with the working surface, it is ofcourse within the scope of the present invention to provide any othersuitable means for raising and lowering the stencil plate or the lflsein such a way as to obtain proper registration with the underlyingsurface to be decorated.

After removal of the guide means or stencil plate, the paper card orother object with the raised decorative body adhering thereto is thenremoved from the working surface. The raised objects or bodies are thenfurther hardened or dried as will be described below.

In order to obtain substantially immediate shape-retaining semihardnessof the composition which is applied to the surface to be decoratedthrough the holes in the stencil plate or the like, the method of thepresent invention employs a hardenable thixotropic composition. Becauseof its thixotropic nature this composition will be come rigid andshape-retaining immediately upon being motionless, that is immediatelyafter being filled into the holes of the stencil plate, and because itcontains a hardenable substance it can be subsequently hardened so as tobecome permanently shape-retaining.

Thus, according to the present invention, initial shaperetenti-on isachieved by the thixotropic nature of the composition and permanentshape-retention by the subsequent hardening process. During thehardenable process, the thixotropic properties of the composition arelost. However, the thixotropic rigidity and shape-retention will beretained for a sufficient length of time until the progressing permanenthardening process has suificiently advanced to maintain the shape of theraised decorative body.

There are generally two steps in forming the finished plastic material;the first is the formation of the polymerizable unsaturated resinouscomposition. Second, the resulting polyester is then polymerized with acompound containing a polymerizable CH =C group.

The polyesters may be defined as polymerizable ethyl enicallyunsaturated polyhydric alcohol-polycarboxylic acid polyesters. Thesepolyesters are generally prepared by the reaction of unsaturatedpolycarboxylic acids and polyhydric alcohols under an inert atmosphereand at elevated temperatures. These polyesters. are weil known in theart, and have been described in numerous plastic encyclopedias andpatents. The reaction is generally carried out until a desired acidnumber or a predetermined extent of csterification is realized. Theresulting unsaturated polyesters obtained are polymerizable.

In the preparation of the polymerizable polyester resinous compositionsethylenically unsaturated polycarboxylic acids such as maleic, fumaric,aconitic, itaconic,

and the like may be used. In addition, acids such as phthalic, malonic,succinic, glutaric, sebacic and the like, may be used. The anhydrides ofthese acids may also be used, e.g., maleic anhydride, phthalicanhydride, and as used herein polycarboxylic acids include thepolycarboxylic anhydrides when available. Also, mixtures of the acidsand anhydrides may be used in the preparation of the polyester resin.

Polyhydric alcohols which may be used in the preparation of thepolyesters include such compounds as ethylene glycol; diethylene glycol;propylene glycol; dipropylene glycol; butanediol-L4; butanedio1-l,3;butanediol-LZ; pentanediol-1,4; pentanediol-1,5; hexanediol-l,6;glycerol, I,1'-isopropylidenebis(p-phenylenoxy)di-Z-propanol,pentaerythritol, dipentaerythritol.

In preparing the polyester, mixtures of one or more of the carboxylicacids or the anhydrides thereof listed above may be mixed with one ormore of the polyhydric alcohols and reacted in an inert atmosphere andat elevated temperatures to provide the polyesters. These techniques andcompositions are well known in the art.

The polymerizable unsaturated polyesters thus formed are then admixedwith a monomeric compound containing the polymerizable CH ==C group togive a composition that may be cured to a stable thermoset condition.Monomeric materials which may be used include such compounds as styrene,side-chain alkyl and halo-substituted styrenes such asalpha-methylstyrene, alpha-chlorostyrene, alpha-ethylstyrene and thelike or alkyl and halo ring-substituted styrene such as ortho-, metaandparaalkyl styrenes such as o-methylstyrene, p-ethylstyrene,m-propylstyrene, 2,4-dirnethylstyrene, 2,5-diethy1styrene, bromostyrene,chlorostyrene, dichlorostyrene and the like. Still further, one can makeuse of the allyl compounds such as dially phthalate, tetrachlorodiallylphthalate, allyl alcohol, methallyl alcohol, allyl acetate, allylmethacrylate, diallyl carbonate, allyl lactate, allylalphahydroxyisobutyrate, allyl trichlorosilane, allyl acrylate, diallylmalonate, diallyl oxalate, diallyl gluconate, diallyl methylgluconate,diallyl adipate, diallyi sebacate, diallyl citraconate, the diallylester of muconic acid, diallyl itaconate, diallyl chlorophthalate,diallyl dichlorosilane, the diallyl ester of endomethylenetetrahydrophthalic anhydride, triallyl tricarballylate, triallylaconitate, triallyl cyanurate, triallyl citrate, triallyl phosphate,trimethallyl phosphate, tetraallyl silane, tetraallyl silicate, hexallyldisiloxane and the like.

After admixing the polyester and monomer, the latter of which mayinclude one or more of the compounds above set forth, a catalytic agentis used to effect the reaction between the polyester and monomer. As iswell known in the art, a catalyst of the peroxide class may be utilized.Examples of catalysts that may be used are such as benzoyl peroxide,succinyl peroxide, acetyl per oxide, methyl ethyl ketone peroxide,cumene hydroperoxide, tertiarybutyl hydroperoxide, cyclohexanoneperoxide, perbenzoic acid, peracetic acid, anisoyl peroxide, toluylperoxide, p-bromobenzoyl peroxide, tertiarybutyl perbenzoate, p-methanehydroperoxide, pinane hydroperoxide, diisopropylbenzene hydroperoxide,titiarybutyl peracetate, 1-cyclohexanol-l-hydroperoxide, furoyl peroxideand chloracetyl peroxide or any organic ozonide, such as diisopropyleneozonide, diisobutylene ozonide or a mixture of such substances. Otherfree radical type polymerization catalysts that may also be used aresuch as a,u-azodiisobutyronitrile, the salts of inorganic peracids,e.g., ammonium persulfate, sodium persulfate and the like.

It will be apparent from the above description of the polyester, monomerand catalyst that by the use of the term polymerizable unsaturatedpolyester resin I mean that resinous material which is the mixture of apolymerizable unsaturated polyester, a monomeric compound containing apolymerizable CH =C group and a suitable peroxide catalyst. Thepolymerizable unsaturated polyester is the reaction product of aselected unsaturated polycarboxylic acid and a polyhydric alcohol.

The particular proportions of ingredients to be used to form the finalresin will be dictated by the particular compounds selected, and is wellwithin the skill of the art.

The uncatalyzed polymerizable unsaturated polyester resin thus formed isrelatively fluid and would, of its own accord, tend to run, or flow. Inorder to hold the material in a predetermined shape during the curingoperation, various thixotropic materials well known in the art may beadded to the unpolymerized material to increase the apparent viscosity.Typical thixotropic agents are hydrogenated castor oil, aluminumpalmitate, aluminum stearate, bentonite and calcium stearate. Thesethixotropic agents convert the relatively fluid polymerizable resin intoa substantially stable gel which will at least for the curing timesinvolved herein, hold the gel in a predetermined shape and form.

The used a thixotropic agent adversely affects the clarity and qualityof the polymerizable unsaturated polyester resin. The mixture of theresin and the thixotropic agent is cloudy and at least semiopaque. Ihave discovered, and as a part of this invention, that if this mixtureis cured under certain time-temperature conditions, the thixotropicagent loses its efiicacy and permits the formation of a clear,transparent body. Accordingly, I have discovered a method by which athixotropic agent may be utilized to hold a polymerizable resin in apredetermined shape during curing and still obtain a clear, transparentcured decorative body which firmly adheres to the surface to bedecorated.

In the catalytic curing of the resulting thixotropic mixture, air tendsto inhibit the surface cure resulting in a residual tackiness. Thissurface tackiness may be prevented or reduced by the addition of certaincompounds well known in the art. Examples thereof are cobalt napthene,parafiin wax and silicon fluid. These additive compounds tend to improvethe quality of the ultimate product but are not necessary if airinhibition of the cure can be otherwise prevented.

To the thixotropic composition used in the method of the presentinvention, coloring materials which are soluble in the polyester resin,as well as solid materials such as metal flakes, tinsel, powder ofmother of pearl and the like may be added. The solid materials added tothe polyester resin are in the unpolymerized resin substantiallyuniformly distributed throughout the mixture. The false viscosity giventhe mixture by the thixotropic agent holds these solid materials insuspension.

I have discovered that if the resin is cured rapidly as, for example, byimmediately subjecting the unpolymerized decorative bodies to atemperature in excess of 200 F., the solid materials are permanentlyentrapped and uniformly distributed throughout the decorative body. Thisuniform distribution does not result in a decorative body having apleasing appearance. However, and as a further part of the presentinvention, I have discovered that if the unpolymerized resin is curedunder predetermined time-temperature conditions, the thixotropic agentbegins to lose its efiicacy at a temperature below the point wherecatalytic curing proceeds rapidly. As the thixotropic agent loses itsefiicacy, apparent or false viscosity of the uncured resin decreasesallowing the solid materials to settle to a substantially uniform layer.By substantially increasing the temperature, rapid curing is efiectedwhereby a decorative body having a realistic gem-like quality is formed.

After the raised ornamental body has been formed on the surface to bedecorated, the same is exposed to such hardening conditions. forinstance elevated temperatures, as will-in connection with theaccelerators, catalysts and the like embodied in the composition-insureproper hardening of the raised decor'ativebody. Preferably a shortperiod such as between 2 and 4 minutes of prehardening at a temperatureof between 100 F.120 F. precedes the final hardening step which may beexecuted at a temperature of between 150 F.220 F. and which, dependingon the heating method employed, may last for between about 2 and 6minutes. When determining the actual hardening conditions, one has alsoto take into consideration the size and shape of the raised ornamentalobjects, e.g., the relationship between volume and exposed surface ofthese objects and thus the speed of heat penetration therethrough.

The hardening conditions, or curing cycle is, as indicated above,performed in two steps. In the first step the card carrying theunpolyrnerized resinous material is subjected to a temperature between100 F. and 120 F. for a period long enough to destroy the efiicacy ofthe thixotropic agent and permit the settling of the added solidmaterials, if any, in the unpolymerized body. The temperature is then,in the second step of curing, raised rapidly to a temperature above 150F. to efiectuate a final cure. It will be understood by those skilled inthe art that the precise curing temperature to be used both in the firstand second stages of cure will be dictated by (1) the temperaturerequired to cause the thix'otropic agent to lose its efii'cacy, and (2)the temperature at which the catalytic cure of the polymerizable resinmay be achieved most expeditiously.

Preferably, after completion of the hardening process, the cards orother decorated objects are permitted to cool for between 5 and 10minutes prior to being packed or otherwise handled.

The heat-curing process may be executed on trays which are placed in anoven in which air of desired elevated temperature circulates, or,preferably, the decorated objects such as Christmas cards are placed on.a conveyor belt which travels through the heating zone at such speedthat the raised decorative bodies areexposed to the desired temperaturefor the desired length of time.

It is also within the scope of the present invention to employ a curingprocess which is actuated by light instead In this case the cards or thelike with the raised of heat. decorative bodies thereon are preferablyplaced on a conveyor belt and exposed thereon for the desired length oftime to ultra-violet rays.

As the thixotropic agent loses its efficacy during the final stages ofcure, the outer surfaces of the portions of unpolymerized materialapplied to the card become relatively fluid and tend to flow. The amountof how I have discovered is very small but is sufficient to allow a thinlayer of unpolymerized resin to become closely incorporated with orabsorbed by the fibers of the paper card. When curing is completed, theresin material which has become absorbed in the paper joins the applieddecorative body and the card. The body thus virtually becomes a part ofthe card and cannot be removed without physically tearing it ed thesurface of the card. It will be apparent that this is superior to themethods previously used in applying decorative bodies to cards where asurface adhesive was used which did not permit the decorative body to bephysically incorporated within at least a portion of the card.

In applying the decorative bodies to the cards the following steps are'followed:

(1) The polyester resin is prepared.

(2) The thixotropic agent and other desirable additives are thoroughlymixed with the polyester resin.

(3) A stencil having predetermined shape and form is applied to the cardto be decorated,

(4) The polyester resin is placed on the stencil and the excess removed.

(5) The stencil is removed, leaving uncured polyester resin in aplurality of predetermined positions and shapes on the card, the'thixotropic agent preventing running of the resin.

(6) The card is introduced into a heating oven where it is first heatedto a temperature below its generally ac cepted cure point, and where thethixotropie agent loses its eilicacy, and the added solid material fallsto form a uniform layer. The heat is then increased steadily for apredetermined time until thorough cure is achieved. The resulting cardhas decorative bodies firmly fixed thereto.

The following are specific examples of the method of forming decorativebodies. In these examples the materials are given in parts by weight.

EXAMPLE NO. I

76 parts propylene glycol, 49 parts maleic anhydride and 74 partsphtha'lic anhydride were introduced into a steam-jacketed reactionvessel. The vessel was covered with a pressure cap having a gas inletand a gas outlet nozzle. Nitrogen gas was introduced into the gas inletnozzle until the area above the added mixture contained only nitrogen atwhich time the inlet and outlet nozzles were closed to maintain an inertatmosphere in the vessel. The reactants were stirred constantly and thevessel heated until approximately 30 parts by weight of water had beenevolved from the reactants. The temperature of the reactants wasmaintained below 200 F. Following the evolution of the water, theresulting polyester was cooled to 100 F. and 0.005 part of the reactioncatalyst methyl ethyl ketone peroxide was added to'the polyester andthoroughly admixed therewith. To the resulting mixture was next added 80parts styrene which in turn was thoroughly mixed throughout thepolyester. The resulting mixture of the polyester, catalyst and styrenemonomer Was a polymerizable unsaturated polyester resin having aviscosity of approximately 1000 centipoises. The resin was relativelyfluid and accordingly would not retain its shape when placed on asurface to be decorated.

To the resin was added 0.5 part hydrogenated castor oil, a thixotropicagent which increased the apparent viscocity of the resin andsubstantially eliminated its tendency to flow. The resulting thixotropicmixture, which was cloudy or milky in appearance, could be stored orused for periods up to three to four hours at room temperature withouthardening, the speed of the reaction being very slow at temperaturesbelow approximately 150 F.

A stencil having openings of predetermined size and shape was thenplaced on a surface to be decorated, more specifically, a Christmascard. The surface of the stencil was covered with the polymerizableresin to completely fill all openings in the stencil. The excess resinwas removed with a squeegee and the material allowed to set for a fewmoments. The stencil was then removed and the card was placed in an ovenhaving a temperature of 120 F. for 3 minutes. During the heating at thistemperature the decorative bodies on the cards maintained the shapeimparted to them by the stencil and as the thixotropic agent began tolose its efiicacy, the individual resin bodies cleared. At the end of 3minutes the composition became clear and entrapped air bubbles presentin the individual bodies because of the previous agitation wereeliminated from the body. After the preliminary heating at 120 F. thetemperature was raised rapidly to 200 F. for 4 minutes at whichtemperature the catalytic curing of the resin occurred very rapidly. Theresulting decorative bodies were hard and clear, i.e., transparent andfirmly adhered to the surface of the card. In removing one of the bodiesfrom the card the card was torn.

EXAMPLE NO. II

The polymerizabie polyester resin was prepared as in Example No. Iexcept that 0.01 part of a 50 percent benzoyl peroxide was used as acatalyst. To the thixotropic mixture was added a red soluble dye to tintthe cloudy mixture a deep red. To this mixture was added and uniformlydistributed throughout a small amount of finely divided tinsel material.The decorative bodies were applied to the card as in Example No. I andthe following curing cycle was used.

The card was first subjected to a temperature of 120 F. for 5 minutesand 6 seconds. The temperature was then rapidly increased to 145 F. andthe card kept at that heat for 3 minutes and 49 seconds. The temperaturewas again increased to 200 F. for 2 minutes and 33 seconds, and finally,the temperature was increased to 250 F. for 2 minutes and 33 seconds. At120 F. the apparent viscosity of the mixture obviously decreased as thetinsel, which was uniformly distributed throughout the applied body,began to settle and the body to become transparent. At the end of the145 F. step the body was clear and a brilliant red, all of the addedtinsel having settled to a uniform layer adjacent the card. No change inphysical appearance was observed after the 200 F. step and after finalcuring at 250 F. a decorative body having a realistic jewel-likeappearance was formed.

Other decorative bodies may be formed in the manner 8 set forth inExamples I and II utilizing the polymerizable unsaturated polyesterresins previously described.

It will be apparent that the precise curing times to be used will bedependent upon the resin selected, the catalytic agent used, thedimensions of the particle applied and the relative humidity.

In general, the decorative body is heated at a temperature and for atime suflicient to permit the thixotropic agent to lose its efiicacy andthe body to clear. The temperature of the body is then promptly raisedto afiect rapid catalytic curing of the resin.

The following are general examples which tend to illustrate thequantities of materials involved.

EXAMPLE No. 111

Heat Hardenable Composition 1 As desired.

The thus-obtained milky heavy liquid material canbe used for 3 to 4hours without hardening. It should not be stored for any longer periodsof time. The decorative raised bodies formed of the above compositionare to be heated for between 2 and 4 minutes at about F. F. Thereby thecomposition becomes clear and transparent, air bubbles disappear, thetinsel or metal flakes sink to the bottom. Subsequently, completehardening of the composition is achieved by heating for about 4 minutesto between 200 F. and 220 F.

Manganese or iron base accelerators may also be used, however bestresults were obtained with cobalt-napthenate. Other organic waxes whichare compatible with polyester resins may be used instead of parafiinwax, as well as other heat catalysts in place of benzoyl peroxide.

EXAMPLE N0. IV

Heat Hardenoble Composition Minimum Maximum quantity, g. quantity, g.

Basic thixotroplc composition including polyester resin n 1, 000 1, 000Solution of 6% cobalt-naphthenate m petroleum spirits 2. 5 15 Parafiinwax (colorless, to be added in hot,

liquid condition) 0. 1 1. 0 Methvl-ethyl-ketoue peroxide 5 20 Siliconresin or silicon fluid (such as is contained in 20% concentration in SF69 of General Electric Co.) 1 10 Dye, tinsel or the like 1 As required.

EXAMPLE NO. V

Ultraviolet Light H ardenable Composition Minimum Maximum quantity, g.quantity, g.

Basic thixotropic composition including polyester resin 1, 000 1, 000Solution of 6% cobaltnaphthenete in petrow lenm spirits 2. o 15 Paratfinwax (colorless, to be added in hot,

liquid condition) 0.1 1.0 Bmwoin 1Q 50 Dye, tinsel or the like 1 Asrequired.

The decorative raised bodies formed'of the above composition are to beheated for between 2 and 3 minutes to about 100 F.120 Ft until thecomposition becomes clear and transparent. Thereafter the objects suchas Christmas cards, decorated with raised bodies of the abovecomposition are exposed, preferably on a moving belt to ultraviolet raysemanating from ultraviolet bulbs. It is thus possible to use the samecuring equipment for heat hardenable and ultraviolet light hardenablecompositions by simply replacing heating bulbs with ultraviolet bulbs.Ultraviolet light hardeuable compositions are preferred in cases Wherethe paper, fabric or the like on which the raised bodies are formedshould not be exposed to temperature above between 100 F. and 150. F.

In the above preferred embodiment of my invention I have described indetail the polymerizable unsaturated polyester resins which are suitablefor use in forming the decorative bodies. It will, however, be apparentto those skilled in the art that any other catalytically curedthermosetting resin maybe substituted for the polyester resin theredescribed.

In order to achieve the desired jewel-like appearance, it will beobvious that only clear resins should be used. Examples of classes ofresins which may be substituted for the polyester resin are epoxy, amino(urea and melamine) phenols or phenolics, alkyd and silicone resins.Each of these resins is capable of cross-linking in the presence of acatalyst to form-a hard, clear gem-like body.

Finally, while unpolymerized resinous compositions may be formed in aWide variety of viscosities, I prefer to use compositions havingviscosities in the range of from 5 O0 to 1500 centipoises.

By utilizing a thixotropic agent to increase the apparent viscosity ofthe resinous composition and by subjecting the resulting thixotropiccomposition to the previously described time-temperature cure cycle, thedecorative bodies may be formed.

It will thus be apparent that in the broadest sense the method which isthe subject of this invention contemplates the formation of athixotropic composition, the destruction of the thixotropic agent byheating at a temperature below the conventional curing temperature ofthe resin and finally, raising the temperature of the resin to effectfinal cure.

From the above it will be apparent that by'the use of the process thusdescribed, a card having a plurality of separate individually shapeddecorative bodies having a wide variety of colors and appearances may beformed and adhered to the surface of a greeting card or the like on amass production basis without the necessity of individually treatingeach body. Hand processing is thus, to a large extent, eliminated. Inaddition, no adhesives are necessary, the body becoming an integral partof the card itself when cured. It will also be apparent from the abovedescription that a wide variety of materials may be used in forming theresin and that the precise curing cycle will be dependent upon theselection of the materials.

Having fully described my invention, it is to be understood that I donot wish to be limited to the precise details of the examples set forthbut my invention is of the full scope of the appended claims.

i claim:

1. The process of decorating a surface with simulated gem-like solidtranslucent elements attached to the surface, and in which are embeddedsolid glittering decorative particles, which comprises: registering saidsurface with a stencil, having openings corresponding to the design tobe produced on said surface; covering the surfaces exposed by thestencil with a mixture of gel-like thixotropic material in which isincluded solid glittering particles, and of suflicient depth to provideraised bodies on the surfaces; said thixotropic material in its normalstate eing milky and serving to adhere to the surfaces without requiringany other adhesive; separating the stencil from the surface; heating thethixotropic material to a temperature of from F. to 120 F. for aperiodsufiicient for the material to clear; and then continuing theheating at an elevated temperature to complete the hardening of thethixotropic material.

2. In a method of forming raised decorative bodies on a surface to bedecorated, the steps comprising: forming a clear liquid polymerizableunsaturated polyester resin; mixing the liquid resin with a thixotropicagent to convert the resin into a substantially stable cloudy gel;applying the stable gel to the surface to be decorated in predeterminedshape and form; heating the gel at a term perature and for a timesuflicient to permit the thixotropic agent to lose its efiicacy and thegel to clear; increasing the temperature of the resulting clear gel toeffect catalytic curing of the resin whereby a raised decorative body isformed.

3. In a method of forming raised decorative bodies on a surface to bedecorated, the steps comprising: reacting an unsaturated polycarbo-xylicacid with a polyhydric alcohol to form a polymerizable unsaturatedpolyester; admixing the polyester with a monomeric compound containing apolymerizable CH =C group and a peroxide catalyst to form a clear liquidpolymerizable unsaturatedpolyester resin; mixing the liquid resin with athixotropic agent to convert the resin into a substantially stablecloudy gel; applying the stable gel to the surface to be decorated inpredetermined shape and form; heating the gel at a temperature and for atime sufficient to permit the thixotropic agentto lose its efiicacy andthe gel to clear; increasing the te-mperature of the resulting clear gelto effect catalytic curing of the resin whereby a raised decorative bodyis formed.

4. In-a method of forming raised decorative bodies on a surface to bedecorated, the steps comprising: reacting an unsaturated polycarboxylicacid with a polyhydric'al cohol to form a polymerizable unsaturatedpolyester; admixingthe polyester with a monomeric compound containing apolymerizable CH =C group and a peroxide catalyst to form a clear liquidpolymerizable unsaturated polyester resin; mixing the liquid resin witha thixotropic agent to convert the resin into a substantially stablecloudy gel; introducing into the substantially stable cloudy gel asoluble colored dye and a plurality of discrete particles of a soliddecorative material to form a homogeneous dyedgel having the pluralityof discrete particles uniformly distributed therethrough; applying thestable gel to the surface to be decorated in predetermined shape andform; heating the gel at a temperature and for a time suflicient topermit the thixotropic agent to lose its efiicacy, the gel to clear andthe solid material to settle to form a uniform layer adjacent thesurface to be decorated; increasing the temperature of the resulting gelto effect catalytic curing of the resin whereby a raised decorative bodyis formed.

5. In a method of forming raised decorative bodies on a surface to bedecorated, the steps comprising: reacting an unsaturated polycarboxylicacid with a polyhydric alcohol to form a polymerizable unsaturatedpolyester; admixing the polyester with a monomeric compound containing apolymerizable CH =C group and a peroxide catalyst to form a clear liquidpolymerizable unsaturated polyester resin; mixing the liquid resin witha thixotropic agent to convert the resin into a substantially stablecloudy gel; introducing into the substantially stable cloudy gel asoluble colored dye and a plurality of dis crete particles of a soliddecorative material to form a homogeneous dyed gel having the pluralityof discrete particles uniformly distributed therethrough; applying thestable gel to the surface to be decorated in predetermined shape andform; subjecting the gel to a temperature in the range of from F. to F.for a period of from 2 to 6 minutes to permit the thixotropic agent tolose its eflicacy, the gel to clear and the solid material to settle toa uniform layer adjacent the surface to be decorated; increasing thetemperature to a maximum of 250 F. for a period of not less than 3minutes to effect catalytic curing of the resin whereby a raiseddecorative body is formed. I

6. In a method of forming raised decorative bodies on a surface to bedecorated, the steps comprising: reacting 76 parts by weight propyleneglycol, 49 parts by weight maleic anhydride and 74 parts by weightphthalic anhydride in an inert atmosphere and with constant agitation ata temperature above 100 F. but below 200 F. until approximately 30 partsby weight water has been evolved to form a polymerizable unsaturatedpolyester; cooling the resulting polyester to 100 F.; adding 80 parts byweight styrene and 0.005 part by weight methyl-ethylketone peroxide tothe resulting polyester to form a polymerizable unsaturated polyesterresin; increasing the apparent viscosity of the resin by admixingtherewith 0.5 part by weight hydrogenated castor oil to form asubstantially stable cloudy thixotropic mixture; applying the stablemixture to the surface to be decorated in predetermined shape and form;subjecting the resulting mixture to a temperature of 120 F. for 5minutes and 6 seconds, increasing-the temperature to 145 F. for 3minutes and 49 seconds, increasing the temperature to 200 F.'for 2minutes 33 seconds and again increasing the temperature to 250 F. for 2minutes and 33 seconds whereby a plurality of raised decorative bodiesis formed.

1 7. In a method of forming raised decorative bodies on a surface to bedecorated, the steps comprising: forming a clear liquid polymerizableresin; mixing the liquid resin with a thixotropic agent to convert theresin into a sub stantially stable cloudy gel; applying the stable gelto the surface to be decorated in predetermined shape and form; heatingthe gel at a temperature and for a time sufiicient to permit thethixotropic agent to lose its eflicacy and the gel to clear; increasingthe temperature of the resulting clear gel to effect catalytic curing ofthe resin whereby a raised decorative body is formed.

8. In a method of forming raised decorative bodies on a surface to bedecorated, the steps comprising: forming a clear liquid polymerizableresin having a viscosity in the range of from 500 to 1500 centipoises;mixing the liquid resin with a thixotropic agent to convert the resininto a substantially stable cloudy gel; applying the stable gel to thesurface to be decorated in predetermined shape and form; heating the gelat a temperature and for a time sufiicient to permit the thixotropicagent to lose its efficacy and the gel to clear; increasing thetemperature of the resulting clear gel to effect catalytic curing of theresin whereby a raised decorative body is formed 9. In a method offorming raised decorative bodies on a surface, the steps comprising:applying a stable gel to said surface in predetermined shape and form,said stable gel consisting essentially of a mixture of a clear, liquidpolymerizable resin and a thixotropie agent; heating the gel at atemperature and for a time sufiicient to permit the thixotropic agent tolose its eflicacy and the gel to clear; increasing the temperature ofthe resulting clear gel to efiect catalytic curing of the resin wherebya raised decorative body is formed.

10. In a method of forming raised decorative bodies on a surface, thesteps comprising: adding fineiy divided tinsel material to a stable gelto form a homogeneous mixture thereof, said gel consisting essentiallyof a mixture of a clear, liquid polymerizable resin and a thixotropicagent; applying said mixture to said surface in predetermined shape andform; heating the mixture at a temperature and for a time sutficient topermit the thixo tropic agent to lose its efiicacy, the gel to clear andthe tinsel material to settle to a uniform layer adjacent said surface;increasing the temperature of the resulting clear gel to eifectcatalytic curing of the resin whereby a raised decorative body isformed.

11. In a method of forming raised decorative bodies on a surface, thesteps comprising: adding finely divided tinsel material to a stable gelto form a homogeneous mixture thereof, said gel consisting essentiallyof a mixture of a clear, liquid polymerizable resin and a thixotropicagent; applying said mixture to said surface in predetermined shape andform; subjecting the mixture to a temperature in the range of from F. toF. for a period of from two to six minutes to permit the thixotropicagent to lose its eificacy, the gel to clear and the tinsel material tosettle to a uniform layer adjacent said surface; increasing thetemperature to a maximum of 250 F. for a period of not less than threeminutes to effect catalytic curing of the resin whereby a raiseddecorative body is formed.

References Cited in the tile of this patent UNITED STATES PATENTS1,616,138 Porter Feb, 1, 1927 2,403,476 Berry et al July 9, 19462,502,926 Chadwick et al Apr. 4, 1950 2,641,587 Norlander et al. June 9,1952 2,712,190 Sobel July 5, 1955 2,857,359 Schollick et a1 Oct. 21,1958

1. THE PROCESS OF DECORATING A SURFACE WITH SIMULATED GEM-LIKE SOLIDTRANSLUCENT ELEMENTS ATTACHED TO THE SURFACE, AND IN WHICH ARE EMBEDDEDSOLID GLITTERING DECORATIVE PARTICLES, WHICH COMPRISES: REGISTERING SAIDSURFACE WITH A STENCIL, HAVING OPENINGS CORRESPONDING TO THE DESIGN TOBE PRODUCED ON SAID SURFACE; COVERING THE SURFACES EXPOSED BY THESTENCIL WITH A MIXTURE OF GEL-LIKE THIXO TROPIC MATERIAL IN WHICH ISINCLUDED SOLID GLITTERING PARTICLES, AND OF SUFFICIENT DEPTH TO PROVIDERAISED BODIES ON THE SURFACES; SAID THIXOTROPIC MATERIAL IN ITS NORMALSTATE BEING MILKY AND SERVING TO ADHERE TO THE SURFACES WITHOUTREQUIRING ANY OTHER ADHESIVE; SEPARATING THE STENCIL FROM THE SURFACE;HEATING THE THIXOTROPIC MATERIAL TO A TEMPERATURE OF FROM 100* F. TO120* F. FOR A PERIOD SUFFICIENT FOR THE MATERIAL TO CLEAR; AND THENCONTINUING THE HEATING AT AN ELEVATED TEMPERATURE TO COMPLETE THEHARDENING OF THE THIXOTROPIC MATERIAL.